PrintFlex Graphics expands capacity with Gallus

One year after installing the first Gallus One in North America, PrintFlex Graphics has confirmed investment in a new Gallus Labelmaster to further expand its capacity and innovate with new product offerings.

After the pandemic highlighted the St. Louis-based company’s need to expand into new markets and invest in more efficient production methods, PrintFlex began tracking the amount of existing short run work it could move to a digital press.

Equipped with a fourteen-unit Gallus EM 280, the company set its sights on the compact Gallus One digital press from Heidelberg. The machine, which prints CMYK+W at up to 230 ft/min (70 m/min) and achieves 85 percent white opacity at top running speed, was installed in December of 2023.

‘Our EM 280 was really designed to handle complex promotional pieces,’ said Liz Pecha-Poelker, CEO of PrintFlex. ‘We’ve been able to offload short runs, even some longer run jobs onto the Gallus One, and it just makes sense.’

According to Pecha-Poelker, the machine is more economical for the company’s less complicated work and opens up capacity on its flexo presses for improved throughput as well as enabling PrintFlex to expand its digital market presence.

‘We believe the Gallus One enables us to achieve the lowest total cost of ownership for digital label production,’ added Pecha-Poelker. ‘We’re having some fun finding the sweet spot for this machine and continue to find ways to enhance our product offerings with it.’

With a web width of up to 13 3/8in (340mm), the Gallus One enables PrintFlex to print material for base wraps for the first time – offering additional in-store promotional opportunities for its customers. The company has also begun producing hybrid work – printing different layers on its digital and flexo Gallus presses for versioning purposes.

‘The color and registration are great. Everyone is thrilled with the results,’ said Pecha-Poelker. ‘We had no previous experience running a press, but with outstanding training from the Heidelberg Gallus team, we were able to learn quickly. It’s very easy to run and clean.’

Looking for ways to further boost efficiency throughout its production, PrintFlex is set to install a new Gallus Labelmaster later this summer.

The new Labelmaster is a multiweb 10-color press, equipped with three die-cutting stations and an AeroLED UV curing system. The highly specialized machine will take over production of one of the company’s older flexo presses and run alongside its existing EM 280.

‘This Labelmaster will be an overall upgrade for us – increased efficiency, better quality, and registration.’

According to Pecha-Poelker, after the company’s operators are fully trained on the machine, day-to-day production will be much easier thanks to the machine’s simple and intuitive operation, short set-up times, and fast job changes.

‘Thanks to the success of the EM 280, we have a lot of confidence in Heidelberg Gallus technology and engineering. We’re excited to continue this partnership moving forward,’ concluded Pecha-Poelker.